Abrasive articles and methods of forming same

Abstract

A coated abrasive article includes a substrate and a plurality of abrasive particles overlying the substrate, wherein at least 5% of the plurality of abrasive particles is tooth-shaped abrasive particles.

What is claimed is: 
     
       1. A coated abrasive article comprising:
 a substrate; and 
 a plurality of abrasive particles overlying the substrate, wherein at least 5% of the plurality of abrasive particles are tooth-shaped abrasive particles, 
 wherein each of the tooth-shaped abrasive particles comprises a body having a length, a width, and a thickness, wherein length>width≥thickness, and wherein the tooth-shaped abrasive particles comprises a body including a tip region including a tip of the body and a base region including a base of the body, wherein the tip region is defined by a taper including a reduction in the thickness of the body over a tip region length; and wherein a greater content of the tooth-shaped abrasive particles have their tip regions oriented closer to the substrate compared to a content of the tooth-shaped abrasive particles having their base regions oriented closer to the substrate. 
 
     
     
       2. The coated abrasive article of  claim 1 , wherein the base region is at an opposite end of the body from the tip region along a length of the body. 
     
     
       3. The coated abrasive article of  claim 1 , wherein the tip region is defined by a taper including a reduction in the width of the body over a tip region length. 
     
     
       4. The coated abrasive article of  claim 2 , wherein the tip region comprises an asymmetric taper including a first surface and a second surface, wherein the first surface has a different contour as compared to the second surface. 
     
     
       5. The coated abrasive article of  claim 4 , wherein the first surface has a greater curvature compared to the second surface. 
     
     
       6. The coated abrasive article of  claim 2 , wherein the base comprises a projection extending from the body, wherein the projection extends at a base angle relative to a longitudinal axis of the body, wherein the base angle is at least 91 degrees and not greater than 180 degrees. 
     
     
       7. The coated abrasive article of  claim 6 , wherein the projection has a base surface including an upper corner and a lower corner spaced apart from the upper corner across the length of the base surface. 
     
     
       8. The coated abrasive article of  claim 7 , wherein the upper corner or the lower corner comprises a corner radius less than a corner radius of the tip. 
     
     
       9. The coated abrasive article of  claim 2 , wherein the base region comprises a base including a base surface, wherein the base surface is angled at an acute angle relative to the longitudinal axis of the body. 
     
     
       10. The coated abrasive article of  claim 2 , wherein the base comprises a base surface having a plurality of peaks, wherein at least one peak of the plurality of peaks has a tip radius less than a tip radius of the tip of the body. 
     
     
       11. The coated abrasive article of  claim 2 , wherein the base includes a first peak and a second peak separated from each other by a first valley as viewed in two-dimensions by a plane defined by the length and thickness of the body or in two-dimensions by a plane defined by the length and width of the body. 
     
     
       12. The coated abrasive article of  claim 10 , wherein the base comprises a primary peak as viewed in two dimensions defined by the length and the width, wherein the primary peak comprises a tip sharpness that is greater than a tip sharpness of the tip of the body. 
     
     
       13. The coated abrasive article of  claim 2 , further comprising an elongated region extending between the tip region and the base region wherein the elongated region defines a region having a change in width or thickness of not greater than 10% over the length of the elongated region. 
     
     
       14. The coated abrasive article of  claim 1 , wherein the base region comprises a greater volume of material than the tip region based on the cross-sectional area of the base region as compared to the tip region. 
     
     
       15. The coated abrasive article of  claim 1 , wherein at least 60% of the tooth-shaped abrasive particles have their tip regions oriented closer to the substrate than their base regions. 
     
     
       16. The coated abrasive article of  claim 1 , wherein the body comprises striations on at least one surface. 
     
     
       17. The coated abrasive of  claim 16 , wherein the striations extend in a direction of the length of the body.